Commodity Production Costs Report

Polyethylene Furanoate Production from Glucose

Polyethylene Furanoate Operating Costs & Plant Construction Costs

300 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $1,499 USD | See Report Editions Prices

This report, in turn, presents the economics of Polyethylene Furanoate (PEF) production from monoethylene glycol (MEG) and glucose syrup in the United States. In this process, a glucose is isomerized to fructose. Then, fructose is converted to methoxy methyl furan (MMF) intermediate, which is oxidized to FDCA. This process is similar to Avantium YXY. FDCA generated and MEG are then polymerized to PEF in melt-phase and solid-state polymerization.

The report provides a comprehensive study of Polyethylene Furanoate production and related Polyethylene Furanoate production cost, covering three key aspects: a complete description of the Polyethylene Furanoate production process examined; an in-depth analysis of the related Polyethylene Furanoate plant capital cost (Capex); and an evaluation of the respective Polyethylene Furanoate plant operating costs (Opex).

The Polyethylene Furanoate production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Polyethylene Furanoate plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Polyethylene Furanoate plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.

Key reference(s): ?

Polyethylene Furanoate Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) MMF Production (2) FDCA Production; and (3) Polymerizations.

MMF production. The glucose content of the feed is first enzymatically isomerized to fructose, and the effluent is passed through ion-exchange resins to separate unreacted glucose from the fructose. The fructose is sent to the furans conversion reactor. There, crystallized fructose is solubilized with a 95 wt.% methanol and sulfuric acid. Fructose is dehydrated to HMF and, due to the excess of methanol, most HMF is converted to MMF. The reactor effluent is sent to a distillation system to recover the solvent, methyl levulinate as by-product, and purified MMF.

FDCA production. Purified MMF is mixed with acetic acid solvent and catalyst in the oxidation reactor to be converted to FDCA. This stream is filtered to recover crude FDCA. The acetic-acid-rich liquid and catalyst are both recovered before being recycled to the process. Crude FDCA is mixed with water and hydrogen in a hydrogenation reactor, where impurities are removed. The effluent from the reactor is crystallized, and purified FDCA is recovered.

Polymerizations. MEG and FDCA are mixed and passed through two agitated and jacketed reactors, in which esterification takes place generating BHEF. The BHEF monomer is fed to an agitated, jacketed reactor, where PEF oligomers are generated. Next, the PEF oligomers condensate in a rotating disc reactor. Here, higher molecular weight PEF chains are generated. MEG is recovered from gaseous effluents and recirculated. The molten PEF is turned into amorphous PEF chips, which are treated and dried before they are crystallized, to not stick together or agglomerate. The crystallized particles are then polycondensed in a long cylindrical hopper-type vessel. The bottle-grade PEF chips are cooled down, separated from dust, homogenized and packed.

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Table of Contents


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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Polyethylene Furanoate production plant examined.

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements.

Plant Cost Breakdowns

Breakdown of Polyethylene Furanoate process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline.

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Polyethylene Furanoate production plant studied.

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation.

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Polyethylene Furanoate plant capacities.

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL).

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

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